case studies implementation of emas in the cleaning material sector 1 etiv - emas technical...

Case StudiesImplementation of EMAS in the Cleaning Material Sector

1ETIV - EMAS Technical Implementation and Verification 1

Project ETIV – EMAS TECHNICAL IMPLEMENTATION

AND VERIFICATION

Prepared by:

Case StudiesImplementation of EMAS in the Cleaning Material Sector


This project has been funded with support from the European Commission. This publication reflects the views only of the author, and the Commission cannot be held responsible for any use which may be made of the information contained therein.

Case StudyImplementation of EMAS in the Cleaning Material Sector


Objectives

ETIV Project

• Development of didactical training material to promote, stimulate and support the implementation of EMAS II Regulation

Case Study

• Supply information on EMAS implementation in a Cleaning Materials Producer, representing a “Case Study” on EMAS implementation



Contents of this case study

Implementation of EMAS in the Cleaning Materials Sector

Company

Knud E. Dan A/SGreve, Denmark



Company Description

• Danish Ltd. company• Founded 1960• 20 employees• Mixes and bottles cleaning materials• Yearly production: 1900 tonnes, sold in

Denmark and exported



BoardBoard

ManagementRepresentativ

e

ManagementRepresentativ

e

AuditorAuditor

Production Manager

Production Manager Purchase

Assistant

Purchase Assistant

Office Assistants

Office AssistantsSales

Consultant

Sales Consultant Purchase

Assistant

Purchase Assistant Production

Assistants

Production Assistants Storage

Assistants

Storage Assistants

Office Manager

Office ManagerStorage

Manager

Storage ManagerSales

Manager

Sales Manager Chemistry

Manager

Chemistry Manager

Organisation diagram



Production processes

Main processes are mixing of products from premixed raw materials, and bottling in to various containers

Production diagram



Production diagram

DispatchDispatch

StorageStorage

BottlingBottling

Mixing raw materials

Mixing raw materials

Packaging material storage


Raw materials storage tanks

Raw materials storage tanks

Receiving raw material

Receiving raw material

Receiving new packaging material

Receiving new packaging material

Receiving used packaging material

Receiving used packaging material

Cleaning packaging material

Cleaning packaging material





Certificates:

• Knud E. Dan holds both quality and environmental certificates:

ISO 9001 ISO 14001 EMAS



Reason for introduction of EMAS

• Company wanted an ”Environmental Profile”• Wanted to be stronger on the market with

”green customers”• ”Environmental Statement” useful



The implemention process

• Geographical demarcation: the production site only, sales division in other part of country not included

• Working environment included in system



1. Environmental Policy

Combined quality and environmental policy

• … identify and minimize potential factors that may cause damage / harm to the environment ...

• … , chemicals and substances are replaced with less polluting through continuous product development …

• … continuous improvements …



Structure of the EMS

• Company structure / foundation• Procedures / Flow diagrams (Process

descriptions)• Descriptions / basic information• Document for analysis• Tables• Tools



Person responsible for document

Company logo

Version Document users Document number Document

approved by … and date

Document name (when printed the document is not under document control)

Simplified level indication

Document control



Management system is computerised. Document access is possible through graphical interface and more traditional documents listings

Computerised EMAS



All envrionmental impacts are listed

Raw materials

Packaging material

Water

Electricity

Gas

Fuel

Products

Packaging materials

Refuse

Wastewater

Emission

Heat

Knud E. Dan A/S



Environmental impacts at Knud E. Dan (consumption)

• Raw materials (chemical substances)• Water• Electricity• Gas• Packaging• Fuel



Environmental impacts at Knud E. Dan (outgoing)

• Chemicals for collection• Refuse for collection• Emmissions to atmosphere



Working environment is also included

• Lay out of working stations• Time pressure• Stress• Working pace



Prioritisation of environmental impacts

• The largest impacts happens at the customer• Packaging material: PVC bottles replaced• Informing customers how to dispose products

and packaging



Objectives and targets

• Evaluated every year• Objectives linked to actual measurable targets• Periodical updating of targets ensures

continous improvement



Examples of targets

• Chemical waste diminished from index 68 to index 65

• Gas usage must not exceed index 95• Electricity consumption maintained at index

120



Lessons learned regarding objectives and targets

• It is important to see results from the start• Therefore: ”pick the easy options first!” – that is

areas with potential for improvement. At Knud E. Dan these were:

Packaging material (PVC replaced - huge effect) Electricity (very likely to give results if no efforts have

been made before. Financial gains also very likely)



Data avaliability

• Data availability may be a problem (data sheets on raw materials)

• Information and measurements must be collected from various sources on various times



Data monitoring must be well organised

• It may be difficult to: Obtain exact data Get data from correct period of time Obtain comparable data

• Knud E. Dan chose to monitor every month and use the financial year as overall period



Goals and resultsEnvironmental impact Goal Measurement in

2002-2003

Raw material labelled “poisonous” (“T”) 20 18

Raw material labelled “dangerous for health”* 60 60

Electricity 120 130

Gas** 95 89

Chemical waste 40 72

Waste re-use (degree of) 15 19

Fuel consumption*** 17 16.6

Fraction of Environmentally labelled products

(“Svanemærket” issued by the Nordic Counsel)

43.9 53.5

Employee satisfaction 50 90



Other improvements and results:

• Possibility of quick follow-up on consumption and other fctors going beyond expected values

• Good understanding and better control of company



Examples of Environmental Management Programmes

• Substitution of cationic tenside by one third• Reuse of rinsing water from certain products• Substitution of PVC packaging• Reduction of harmful raw materials by

substitution• Materials for trays and cartons for packing of

productis must be recycleable



Structure and responsibility

• Environmental manager is responsible for the bulk of the management system procedures

• Other employees responsible for daily working routine instructions

• Management groups for main areas: Production Storage Buying / expedition Sales



Training, awareness and competence

• All employees trained at introduction of system• Training by doing works well• Employee skills are registered in employee

registrations records



Communication with community and other interested parties

• Website with information on company• Environmental satatement available on website

– updated every year• Strict procedures in-house tell who is

authorised to communicate with the press



EMS internal environmental audit

• Performed by different audit teams for different areas

• Audit teams are trained in audit and EMS• Audits are performed using audit checklists



Management review

• Performed by management and middle management

• Performed yearly – but more often if necessary (special projects)

• Environmental projects and non-conformances are evaluated



Internal gains of EMAS

• Powerful tool in company management• Environmental improvements• Some economic savings



External gains of EMAS

• Knud E. Dan was expecting more sale, but it has only had limited effect

• EMAS symbol is used for marketing



Overall evaluation of EMAS at Knud E. Dan A/S

• EMAS has helped the company organise itself internally

• EMAS has made the company more environmentally friendly

• EMAS has made the company save on energy and raw materials

• EMAS has provided a certified environmental statement

case studies implementation of emas in the cleaning material sector 1 etiv - emas technical...

Documents

emas implementation

emas slide

cleaning material sector

introduction of emas

new packaging material

cleaning materials producer

denmark slide

premixed raw materials